MILLING MACHINE

INTRODUCTION
A milling machine is a machine tool that removes metal as the work is moved against
rotating multipoint cutter. The milling cutter rotates at high speed and it removes metal at very
high rate with the help of multiple or many cutting edges. One or many number of cutters can
be mounted simultaneously on the arbor of milling machine. This is the reason that a milling
machine finds wide application in mass production work. Milling machine is used for
machining flat surfaces, contoured surfaces, surfaces of revolution, external and internal
threads, and helical surfaces of various cross-sections.

MILLING METHODS
1. Up-milling or conventional milling, in this method the metal is removed in form of small
chips by a cutter rotating against the direction of travel of the work piece.
2. Down milling or climb milling, in this method the metal is removed by a cutter rotating
in the same direction of feed of the work piece.

TYPES OG MILLING CUTTERS

Milling cutters are made in various forms and they are classified as:
1. Plain milling cutters,
2. Side milling cutters,
3. Face milling cutter,
4. Angle milling cutters,
5. End milling cutter,
6. Fly cutter,
7. T-slot milling cutter,
8. Formed cutters,
9. Metal slitting saw,

TYPES OF MILLING MACHINES

Various types of milling machine are listed below
1. Column and knee type milling machines
(a) Hand milling machine
(b) Horizontal milling machine
(c) Universal milling machine
(d) Vertical milling machine
2. Planer milling machine
3. Fixed-bed type milling machine
(a) Simplex milling machine.
(b) Duplex milling machine.
(c) Triplex milling machine
4. Machining center machines
5. Special types of milling machines
(a) Rotary table milling machine.
 (b) Planetary milling machine.
(c) Profiling machine.
(d) Duplicating machine.
(e) Pantograph milling machine.
(f) Continuous milling machine.
(g) Drum milling machine
(h) Profiling and tracer controlled milling machine.

BASE
It is a parent member for all the other parts, which rest upon it. It carries the column at its
one end. In some machines, the base is hollow and serves as a reservoir of cutting fluid.
COLUMN
The column is the primary and main supporting member mounted vertically on the base.
It is square or box shaped, heavily ribbed inside and houses all the kinematic and driving
mechanism for the spindle and table feed. The front vertical face of the column is accurately
machined and it is provided with dovetail guide way for supporting the knee.
KNEE
The knee is a rigid grey iron casting which moves up and down on the vertical ways of
the column face. An elevating screw mounted on the base is used to adjust the height of the
knee and it also helps the knee. The knee houses the feed mechanism of the table, and different
controls to operate it.
SADDLE
The saddle is mounted on top of the knee and it moves on guide ways set exactly at 90°
to the column face. The top of the saddle provides guide-ways for the table.
TABLE
The table rests on the saddle and moves longitudinally. A lead screw under the table joins
a nut on the saddle to move the table horizontally by manual effort or power. In universal
machines, the table may also be swiveled horizontally. For this purpose only the table is
mounted on a round base. The top of the table is accurately finished and T -slots are provided
for clamping the work and other fixtures on it
OVERHANGING ARM
It is placed on the top of the column that extends beyond the column face and serves as a
bearing support for the other end of the arbor.
FRONT BRACE
It is an extra support, which is fitted between the knee and the over-arm to ensure further
rigidity to the arbor and the knee.
SPINDLE
Spindle is situated on the upper part of the column and gets power from the motor via
belts, gears, clutches and transmits it to the arbor.
ARBOR
It is like an extension of the machine spindle on which the milling cutters is mounted and
rotated. The arbors are made up with taper shanks for proper alignment for the machine spindles
having taper holes at their nose. The draw bolt is used for managing and locking the arbor with
the spindle and the whole assembly. The arbor assembly consists of the following components.
 1. Arbor 2. Spindle
3. Spacing collars 4. Bearing bush
5. Cutter 6. Draw bolt
7. Lock nut 8. Key block
9. Set screw

CAPACITY OF A MILLING MACHINE

TYPICAL FEASIBLE
Shapes: Solid: Cubic Flat
Solid: Complex Thin-walled: Cylindrical
Thin-walled: Cubic
Thin-walled: Complex
Solid: Cylindrical
Part size: Length: 0.04 - 72 in
Width: 0.04 - 72 in
Materials: Metals Ceramics
Alloy Steel Composites
Carbon Steel Lead
Cast Iron Nickel
Stainless Steel Tin
Aluminum Titanium
Copper Elastomer
Magnesium Thermoplastics
Zinc Thermosets
Surface finish - Ra: 32 - 125 μin 8 - 500 μin
Tolerance: ± 0.001 in. ± 0.0005 in.
Max wall thickness: 0.04 - 40 in. 0.04 - 72 in.
Quantity: 1 - 1000 1 – 1000000

DESIGN RULES WORKPIECE

 Choose the material that minimizes overall cost. A less expensive work piece may result
in longer cut times and increase tool wear, increasing the total cost
Reduce the amount of milling that is required by pre-cutting the work piece close to the
desired size and shape
Choose the size of the work piece such that a large enough surface exists for the work
piece to be safely clamped. Also, the clamped surface should provide clearance between the
tool and the fixture for any cuts

FEATURES
Reduce the number of setups that are required by designing all features on one side of the
work piece,
Design of parts, such as holes and threads, to require tools of standard sizes
Reduce the number of tools that are needed
Make sure that the depth of any feature is less than the tool length and therefore will
avoid the direct contacting the work piece
Fewer requirements for tolerance and surface roughness, in order to reduce costs
Avoid very larger and thin features
Use chamfers rather than a corner radius for outside horizontal edges
Avoid undercuts

MATERIAL COST
The material cost is calculated by the quantity of raw material stock that is required and
the unit price of that stock. The amount of stock is determined by the work piece size, stock
size, process of cutting the stock, and the production quantity. The unit price of the material
stock is affected by the material and the work piece structure. Also, any cost attributed to
cutting the work pieces from the stock also contributes to the total material cost.
PRODUCTION COST
The production cost is a result of the total production time and the hourly wages for
labors. The production time is calculated including the setup time, load time, cut time, idle time,
and tool replacement time. Reducing any of these time components will reduce cost. The setup
time and load time are dependent upon the skill of the operator. The cut time depends upon
many factors that affect the cut length and feed rate. The cut length can be shortened by
optimizing the number of operations that are required and reducing the feature size if possible.
The feed rate is affected by the operation type, work piece material, tool material, tool size, and
various cutting parameters like axial depth of cut. Lastly, the tool replacement time is a result of
the number of tool replaced which is discussed regarding the tooling cost.

TOOLING COST
The tooling cost for machining a work piece is determined by the total number of cutting
tools required and the unit price for each tool. The quantity of tools depends upon the number of
unique tools required by the various operations to be performed and the amount of wear that
each of those tools experience. If the tool wear exceeds the lifetime of a tool, then a
replacement tool must be purchased. The lifetime of a tool is dependent upon the tool material,
cutting parameters such as cutting speed, and the total cut time. The unit price of a tool is
affected by the tool type, size, and material.

POSSIBLE DEFECTS
Most defects in milling are error in a feature's dimensions or surface roughness. There are
many possible causes for these defects, including the following:
INCORRECT CUTTING PARAMETERS
If the cutting parameters such as the feed rate, spindle speed, or axial depth of cut are too
high, the surface of the work piece will be rougher than desired and may contain scratch marks.
Also, a large depth of cut may result in vibration of the cutter and cause inaccuracies in the cut.
DULL CUTTER
As a cutter is used, the teeth will wear down and become inaccurate. A dull cutter is less
capable of making precision cuts.
UNSECURED WORK PIECE
If the work piece is not firmly clamped in the fixture, the friction of milling may cause it
to shift and alter the desired cuts.

ENVIRONMENTAL ASPECTS AFFECTED

METAL CHIPS
The creation of spent cutting fluids and metal chips are the two major wastes streams.
The EPA specifically exempts recycled metal from hazardous waste. The key pollution
prevention issue in recycling metal chips is separating the metalworking fluids from the chips

SLUDGE
If the sump sludge is found non-hazardous, it may be possible to dispose it at a landfill
following approval from local landfill authorities. Otherwise, it must be managed and disposed
as a hazardous waste

AIR EMISSIONS
Evaporating cutting fluids, fluid mist and smoke are generated in machining. They are
not considered environmental impacts but they cause health problems. There are actually oil
mist collectors that avoid this problem

DRY MACHINING
Machining without the use of any cutting fluid, create friction and adhesion between the
tool and the work piece will be in larger amount.

APPLICATIONS
Machine components, engine components

ADVANTAGES
1. All materials compatible
2. Very high tolerances
3. Reduced lead times
DISADVANTAGES
1. Restricted shape complexity
2. Part will require several operations and machines
3. High equipment cost
4. Significant tool wear
5. huge amount of scrap

PRE-OPERATIONAL AND OPERATIONAL SAFETY CHECKS

1. Make sure no slip/trip hazards are in workspaces and walkways.
2. Make sure you are familiar with the operation of the ON/OFF starter and E-Stop (if
fitted).
3. Do not leave equipment on top of the machine.
4. Check whether the machine guards are in position.
5. Make sure that the cutter is in good condition and securely mounted.
6. Check whether the coolant delivery system to allow for sufficient flow of coolant.
7. Damaged equipment’s must not be used. Immediately report suspect machinery.

POTENTIAL HAZARDS
1. Sharp cutters, 2. Moving components - hair/clothing entanglement, 3. Eye injury

4. Skin irritation, 5. Metal splinters and burrs, 6. Flying debris.

TECHNICAL DATA OF CONVENTIONAL MILLING MACHINE

F1200 E F1210 E F1410 LF

Longitudinal X-axis 260 mm 500 mm 500 mm
Vertical Z-axis 280 mm 280 mm 280 mm
150 mm 150 mm
Transverse Y-axis 200 mm
optional 180 mm optional 180 mm
Power 230 V, 50 Hz 1,4 kW 1,4 kW 1,4 kW
Spindle speed infinitely
140 - 3000 r.p.m. 140 - 3000 r.p.m. 140 - 3000 r.p.m.
variable
Swivel range of the
milling head to both 90° 90° 90°
sides
 MT2 MT2 MT2
tightening thread tightening thread tightening thread
M10 M10 M10
Tool holder optional MT3 or optional MT3 or optional MT3 or
SK30 SK30 SK30
tightening thread tightening thread tightening thread
M12 M12 M12
Drilling stroke 55 mm 55 mm 55 mm
Milling table 450 x 180 mm 700 x 180 mm 700 x 180 mm
Number of T-slots 3 3 3
Width of T-slots 12 mm 12 mm 12 mm
Truth of rotation of
0,01 mm 0,01 mm 0,01 mm
spindle nose
Distance between
min. 100 mm min. 90 mm min. 65 mm
milling machine table
max. 380 mm max. 370 mm max. 350 mm
and spindle nose
Working range of
spindle nose and 185 mm 185 mm 185 mm
support column
Machine dimensions (W 650 x 640 x 960 900 x 610 x 960 950 x 600 x 950
x D x H) mm mm mm
Weight without packing 85 kg 101 kg 118 kg
F1200 E F1210 E F1410 LF
high speed high speed high speed
Power 230 V, 50 Hz 2,0 kW 2,0 kW 2,0 kW
Spindle speed 100 - 7500 r.p.m. 100 - 7500 r.p.m. 100 - 7500 r.p.m.
Machine dimensions (W 700 x 600 x 1100 950 x 600 x 1100 950 x 600 x 1100
x D x H) mm mm mm
Weight without packing 96 kg 112 kg 127 kg

CALCULATION ON MILLING MACHINE

Terms Used:
N: RPM of Cutter
n: Number of Teeth on Cutter
W: Width of cut (may be full cutter or partial cutter)
t: depth of cut
V: cutting speed -- a Handbook value
L: Length of pass or cut
fm: Table (machine) Feed
ft: feed/tooth of cutter -- a Handbook value
D: Cutter Diameter

A. Cutting Speed:

If Cutting Speed for a given RPM rate is desired, solve above equation for V: V = ND/k

B. Table Feed Rate:

C. Cutting Time:
D. Material Removal Rate: